# US 10,479,520 B2 · Composite structure assembly having an interconnected layered core

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- Number: US 10,479,520 B2
- Document ID: US10479520B2
- Status: Granted
- Kind: B2
- Application number: 15/604,697
- Filed: 2017-05-25
- Published: 2018-11-29
- Granted: 2019-11-19
- Earliest claimed: 2017-05-25
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: John C. Waldrop, III; Zachary Benjamin Renwick; Matthew Scott Thompson; Michael William Hayes
- Web page: https://patentgrep.com/patent/US10479520B2

## CPC

- B64D 33/02: of combustion air intakes
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/285: {comprising polyethers}
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/288: {comprising polyketones}
- B32B 27/34: comprising polyamides
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B64D 27/16: of jet type
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2305/024: Honeycomb
- B32B 2307/102: Insulating
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2605/18: Aircraft
- B64D 2033/0206: {comprising noise reduction means, e.g. acoustic liners}
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A composite structure assembly and method of forming a composite structure assembly is provided. The composite structure assembly includes a composite core including a first cell layer having a plurality of first cells and a second cell layer having a plurality of second cells. The first cell layer is adjacent to the second cell layer. The plurality of first cells are fluidly interconnected with the plurality of second cells.

## Claims

### Claim 1

A composite structure assembly, comprising:
a composite core including a first cell layer having a plurality of first cells and a second cell layer having a plurality of second cells, wherein the first cell layer is adjacent to the second cell layer, and wherein the plurality of first cells are fluidly interconnected with the plurality of second cells; and
a plurality of connecting beams that connect the first cell layer to the second cell layer.

### Claim 2 (depends on 1)

The composite structure assembly of claim 1, wherein each of the plurality of first cells is in fluid communication with at least two of the plurality of second cells, and wherein each of the plurality of second cells is in fluid communication with at least two of the plurality of first cells.

### Claim 3 (depends on 1)

The composite structure assembly of claim 1, wherein the first cell layer is offset with respect to the second cell layer.

### Claim 4 (depends on 3)

The composite structure assembly of claim 3, wherein the first cell layer is rotationally offset with respect to the second cell layer.

### Claim 5 (depends on 3)

The composite structure assembly of claim 3, wherein the first cell layer is linearly offset with respect to the second cell layer.

### Claim 6 (depends on 3)

The composite structure assembly of claim 3, wherein the first cell layer is offset with respect to the second cell layer through a difference in one of both of shape or size between the plurality of first cells and the plurality of second cells.

### Claim 7 (depends on 1)

The composite structure assembly of claim 1, wherein the first cell layer comprises a plurality of first cross members that define the plurality of first cells, wherein the first cross members are parallel to one another.

### Claim 8 (depends on 7)

The composite structure assembly of claim 7, wherein the second cell layer comprises a plurality of second cross members that define the plurality of second cells.

### Claim 9 (depends on 8)

The composite structure assembly of claim 8, wherein the plurality of first cross members are perpendicular to the plurality of second cross members.

### Claim 10 (depends on 8)

The composite structure assembly of claim 8, wherein the plurality of first cross members are linearly shifted in relation to the plurality of second cross members.

### Claim 11 (depends on 8)

The composite structure assembly of claim 8, wherein each of the plurality of first cross members differs in one or both of size or shape from each of the plurality of second cross members.

### Claim 12 (depends on 1)

The composite structure assembly of claim 1, wherein the plurality of first cells are staggered in relation to the plurality of second cells to provide increased structural support for a skin.

### Claim 13 (depends on 1)

The composite structure assembly of claim 1, further comprising at least one skin secured to the composite core.

### Claim 14

A method of forming a composite structure assembly, the method comprising:
forming a first cell layer having a plurality of first cells;
forming a second cell layer having a plurality of second cells; and
securing the first cell layer to the second cell layer to form a composite core, wherein the first cell layer is adjacent to the second cell layer, wherein the securing fluidly interconnects the plurality of first cells with the plurality of second cells, and wherein the securing comprises connecting the first cell layer to the second layer with a plurality of connecting beams.

### Claim 15 (depends on 14)

The method of claim 14, wherein the securing comprises:
fluidly coupling each of the plurality of first cells with at least two of the plurality of second cells; and
fluidly coupling each of the plurality of second cells with at least two of the plurality of first cells.

### Claim 16 (depends on 14)

The method of claim 14, wherein the securing comprises offsetting the first cell layer with respect to the second cell layer.

### Claim 17 (depends on 16)

The method of claim 16, wherein the offsetting comprises one or more of: rotationally offsetting the first cell layer with respect to the second cell layer, linearly offsetting the first cell layer with respect to the second cell layer, or offsetting the first cell layer with respect to the second cell layer through a difference in one of both of shape or size between the plurality of first cells and the plurality of second cells.

### Claim 18 (depends on 14)

The method of claim 14, wherein the forming the first cell layer comprises providing a plurality of parallel first cross members that define the plurality of first cells, and wherein the forming the second cell layer comprises providing a plurality of parallel second cross members that define the plurality of second cells.

### Claim 19 (depends on 18)

The method of claim 18, further comprising orientating the plurality of parallel first cross members to be perpendicular to the plurality of parallel second cross members.

### Claim 20 (depends on 18)

The method of claim 18, further comprising linearly shifting the plurality of parallel first cross members in relation to the plurality of parallel second cross members.

### Claim 21 (depends on 14)

The method of claim 14, wherein the securing comprises staggering the plurality of first cells in relation to the plurality of second cells to provide increased structural support for a skin.

### Claim 22 (depends on 21)

The method of claim 21, further comprising securing at least one skin to the composite core.